Text by Ned McMahon David Pu'u
Yater in the Shaping Room
The past few months have been an interesting roller coaster ride
for the U.S. surfboard industry, which was plunged into panic after the
abrupt closure of Clark Foam. Now, after seven or eight months of dire
foam shortages, we seem to be facing in the domestic market an
overabundance of polyurethane blanks. In the uncertainty following
Clark's demise, the door of opportunity has been thrown wide open to a
bewildering array of materials and manufacturing methods, some of them
new, some of them long-standing. Many of these 'emerging' materials
have hovered on the fringes of the surf industry for years, while other
technologies finally found a breathing hole in which to surface.
It is important that we consider all these many alternatives to
ensure that we are using the best materials and construction methods to
make our beloved surfboards. In determining the 'best,' of course, we
must look at many factors - strength, durability, environmental impact,
aesthetics, ease of production and cost. And the astute board builder,
after investigating all the alternatives, once again concludes that
polyurethane foam makes the best core for most surfboards.
All surfers owe a debt of gratitude to Gordon Clark. For over 40
years he has given us a high-quality, durable material that was
affordable, easy to work with, and simple to customize. Clark's
persistent advances in his product quality and variety (especially the
addition of his line of close tolerance blank plugs pioneered by Pat
Rawson and Rusty Preisendorfer) allowed many surfers to take up
shaping, many of whom might never have even attempted to do so had the
blanks and foam densities remained crude and oversized.
Clark continued to develop his product right to the very end. Even
as he was forced to shut down he was still working on new formulations,
and was actively looking for the next product or tool improve his
product or factory.
Now, it's a whole new world out there. Both the surfboard builder
and the layman customer are faced with a bewildering choice of
materials from which to build surfboards. Some materials and methods,
such as the hollow carbon and parabolic wood railed construction, offer
fantastic technology and produce great boards, but they aren't
practical for large production runs, nor do they allow for the intimate
customization that many surfers have become accustomed to.
Lately, polystyrene foams like EPS (expanded polystyrene) have
made some big inroads to the market. To some, EPS appears to be the
best alternative to polyurethane foam. Use of polystyrenes as surfboard
cores dates back to WWII and its development as part of the war effort,
though interest in it has waxed and waned many times. When Gordon Clark
first began producing blanks he had the opportunity to use polystyrene,
too - so why, we wonder, did he choose to work only with polyurethane?
Polystyrenes come in either extruded or expanded (from bead) form.
Extruded foams come in big blocks that must be cut with a hotwire into
blank form prior to the stringer glue-up. Expanded polystyrenes mostly
come in block form, too, although some manufacturers expand the
polystyrene beads in molds just like regular blanks. As the molds are
metal, they are very expensive and difficult to make. And in the end,
EPS foams are troublesome and hard to shape cleanly.
Polystyrene does have a few advantages over polyurethane. One plus
is that the foam can be formulated in very light densities. Another is
that they maintain an even strength because, whereas molded
polyurethane blanks get softer toward the center, polystyrene foams
possess a constant density throughout. Some surfers also like the
liveliness and feeling of greater buoyancy offered by polystyrene
boards.
However, polystyrenes do have their disadvantages. For one, whether
extruded or expanded, they must be glassed with an epoxy resin. Epoxy
resins are more likely to cause adverse reactions in workers handling
them than do the polyester resins commonly used with polyurethane foam.
EPS blanks are usually glassed with some sort of opaque color scheme
because they are tougher to finish-shape as smoothly as polyurethane
foam. And because of the bead composition of EPS foams, they can be
tricky to shape and must be spackled or otherwise sealed before
glassing. But perhaps the biggest drawback is that both extruded and
expanded polystyrene blanks must be meticulously glassed: extruded
foams have a history of core-to-skin bond failure, and EPS blanks, once
encased in the fiberglass skin, can suck incredible amounts of water
through the tiniest pinhole. Furthermore, while many surfers rave about
the lightweight boards resulting from use of these materials, just as
many disdain the inherent stiffness of the polystyrene foam sandwich
construction.
So, all these drawbacks bring us right back to polyurethane. As a
core for most surfboard types it bestows numerous benefits: its
components are relatively inexpensive, and are expanded in molds that
are fairly inexpensive and easily made, therefore allowing a wide
selection of blank sizes and shapes. It is easy to work with, and
responds magnificently with common tools and sandpaper. Because it can
be finished so smoothly, polyurethane allows a consistency and fine
detail in with resin tinting and airbrushing that it hard to beat,
granting to the builder and customer the potential for infinite
customization. There are drawbacks, of course. Some production problems
can arise, including: air bubbles in the foam; pour streaks and marks
caused by uneven distribution of the resins in the mold; inconsistent
density and soft spots from improperly measured volume and placement of
the resins in the mold; and softer areas pooling in the center of the
blank.
TDI (toluene diisocyante), a reactive agent in most polyurethane
foams and the primary culprit in the demise of Clark Foam, is on its
way to being legislated out of the U.S., though some factories are
still allowed to use it because of grandfather clauses and expensive
factory retrofits. Painstaking industrial hygiene must be practiced
when workers handle TDIs. Surfers are growing more and more aware of
environmental issues and are taking a good hard look at the nasty
components of their surfboards. Yet, in the wake of the Clark Foam
closure, and its subsequent indictment of TDIs, several start-up blank
manufacturers have set up shop just south of the California border, in
order to take of advantage of cheap labor and, more importantly, to use
TDIs unhindered by EPA issues in the U.S.
Right now, thousands of blanks are streaming into the U.S. from
factories around the world - South Africa, Brazil, Argentina, Spain,
Australia, China, and the UK. The vast majority of these manufacturers
use TDI in their blanks. In addition to the various tolls exacted by
this known carcinogen, it seems to me that shipping containers of a
lightweight product like foam around the world is wasteful and just
doesn't make sense. Having the cores of our supposedly 'green'-oriented
surfcraft hauled all over the planet by the shipping container network
is hardly 'green' thinking. Shipping just the raw materials needed to
make a foam blank is at least 18 times more fuel-efficient than
shipping the whole blank.
However, there is another type of polyurethane foam now available,
one using MDI (methylene di-phenyl di-isocyanate) instead of TDI. Even
Gordon Clark was experimenting with MDI-based foam before he called it
quits. The main health hazard associated with isocyanates stems from
the inhalation of aerosols, which can cause respiratory problems. When
molding rigid foams such as surfboard blanks, there is the additional
hazard of partially cured foam dust being released into the air during
the de-molding process. MDI, with a vapor pressure of some 2500 times
less than that of TDI at ambient temperatures, is by far the least
hazardous of the commonly available isocyanates. This means that the
molding pressure is much less and, therefore, a part out of the mold is
more fully cured. According to NIOSH (National Institute for
Occupational Safety and Health), studies have demonstrated that
commercial grade TDI is carcinogenic in rats and mice and therefore TDI
is a substance "which may be reasonably anticipated to a carcinogen."
A modern MDI-based blank plant, such as Homeblown U.S. in San
Diego, relies on a computer-controlled pouring machine that ensures the
resins are delivered precisely in the correct amount to the mold's
extremities. This results in an astonishing consistency - with minimal
waste - in blank manufacture. Air voids and pour marks are eliminated
and a consistent density and hardness is achieved throughout the blank.
The resulting MDI-based foam blanks are 15% to 25% stronger in
compression strength than any other TDI foam of comparable density,
according to the results of independent testing. MDI-based foams are
rated ten times more waterproof than those based on TDI, and so suffer
much less saturation when dinged. The consistent density throughout
allows for very clean CNC shaping with no concerns about softer foam
toward the center of the blank. The smaller cell structure is excellent
for color work and absorbs less resin, resulting in lighter and
stronger boards overall. While some builders might worry about about
delamination, this isn't seen as a factor because delamination
typically occurs when foam separates from itself - which is far less
likely with MDI-based foam.
Finally, we are right back where we started. The surfboard builder
and customer faces a wider array of surfboard materials and composite
technologies than ever before - yet we find ourselves circling back to
polyurethane again and again. Way back in 1960 Gordon Clark recognized
it was a fantastic material for the mass production of surfboards. A
chemical engineer, he had in his over his nearly 45 years of successful
blank manufacture countless opportunities to experiment with myriad
materials - and yet polyurethane always won out. Ultimately, he
realized - as we must - that polyurethane is the easiest foam to work
with, allows for beautifully colored, customized surfboards, and is
strong, flexible and relatively inexpensive. It is still the best
choice for a surfboard core. The bane of polyurethane foam manufacture
has always been the use of TDI rather than MDI. All the TDI-based foams
in the world can - at their best - only hope to pick up where Clark
left off. Gordon Clark knew that MDI-based foam was the future of
polyurethane, and polyurethane is still the future of surfboards - and
surfing.